Luminance enhancement film having a substrate incorporation dispersed particles for diffusion

ABSTRACT

The present invention discloses a light redirecting film. The light redirecting film comprises a support substrate and an optical substrate. The support substrate comprises a unitary body, wherein the unitary body has a first surface and a second surface opposite to the first surface. The optical substrate has a third surface and a fourth surface opposite to the third surface, wherein the fourth surface is a structured surface, and the second surface of the unitary body faces the third surface of the optical substrate. A plurality of particles are disposed in a region below the first surface of the unitary body, wherein the thickness of the region is smaller than the thickness of the unitary body.

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/455,021 filed on May 26, 2009, which claims priority of U.S.Provisional Application Ser. No. 61/128,813 filed on May 23, 2008. Allof these applications are incorporated by referenced herein in theirentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to optical substrates having a structuredsurface, particularly to optical substrates for brightness enhancement,and more particularly to brightness enhancement substrates for use inflat panel displays having a planar light source.

2. Description of Related Art

Flat panel display technology is commonly used in television displays,computer displays, and handheld electronics (e.g., cellular phones,personal digital assistants (PDAs), etc.). Liquid crystal display (LCD)is a type of flat panel display, which deploys a liquid crystal (LC)module having an array of pixels to render an image. Referring to FIG.1, a common backlight apparatus 10 for LCD comprises a reflector 11, alight guide 12, a light source 13, various optical films including lowerdiffuser sheet 14, two crossed brightness enhancement films 15 (e.g.,two sheets having similar surface structures, with the sheets offset by90 degrees about an axis perpendicular to the plane of the sheets), andan upper diffuser 17.

The brightness enhancement films 15 use micro-structures to direct lightalong the viewing axes (i.e., normal to the display), which enhances thebrightness of the light viewed by the user of the display and whichallows the system to use less power to create a desired level of on-axisillumination. Heretofore, brightness enhancement films have a lightinput surface that is smooth, through which light enters from thebacklight module, and a structured light emitting or output surfaceprovided with micro-structures (e.g., prisms, lenticular lenses orpyramids). The micro-structures provided at the light emitting surfacechanges the angle of the film/air interface for light rays exiting thefilms and causes light incident obliquely at the light input surface ofthe films to be redistributed in a direction more normal to the lightemitting surface of the brightness enhancement films.

The brightness enhancement films may be in the form of micro-prismaticsheets. The composition of a micro-prismatic sheet (such as 3M™prismatic brightness enhancement films) generally comprises two layers,including a PET substrate 16 and a structured layer 18 (e.g., an acryliclayer) having micro-prism structures. The function of the structuredlayer 18 having a light output surface with micro-prism structures is tocollect the light toward the viewer after being scattered by the lowerdiffuser 14. The PET substrate 16 is a relatively stronger layer thatsupports the relatively weaker micro-prism layer 18.

It has been proposed to apply one multifunctional film to replace two orthree optical films mentioned above. The multifunctional film needs toachieve both functions of light enhancement and the diffusion functionof upper/lower diffuser. Heretofore, various approaches had beendescribed in the prior art.

FIG. 2 illustrates a prior art “Type-A” multifunctional film 20.Particles are added to the acrylic prism layer 28 supported by thesubstrate 26. (See, for example, U.S. Patent Publication No.US2007/0121227.)

FIGS. 3 and 4 illustrate prior art “Type B” multifunctional films. Forthe multifunctional film 30 illustrated in FIG. 3, a separate coating 32of a resin containing particles/beads is applied to the bottom surfaceof the substrate 36 that supports the prism layer 38. Similarly, in FIG.4, a separate coating 42 of particles are applied to the bottom surfaceof the substrate 46 that supports the structured layer 48. (See, forexample, U.S. Pat. Nos. 5,995,288, 6,147,804, 6,333,817, 6,560,023,6,700,707, 6,825,984, 6,280,063, JP3968155, JP3913870, and JP3860298.)The Type-B multifunctional film is generally made by depositing an UVcurable resin onto the PET substrate and then embossing with a mastermold (see, e.g., U.S. Pat. No. 5,183,597) to form the structured layer,and using a conventional solvent casting method to form the additionallayer resin layer having particles.

FIG. 5 illustrates a prior art “Type C” multifunctional film 50, whichhas structured surface 58 and diffusing surface 52 integrally formed ontop and bottom sides of a substrate sheet 56. The structured surface 58and diffusing/scattering surface 52 may be produced by extruding orcalendaring the sheet 56 between two rolls or belts with differentpatterns corresponding to the structured surface 58 anddiffusing/scattering surface 52. U.S. Pat. No. 6,280,063 discloses hotembossing micro-prisms to form the structured surface 58 and thediffusing/scattering surface 52 on extruded sheet 56.

U.S. Pat. No. 5,598,280 discloses another example of a Type-Cmultifunctional film 60, in which a light-diffusing surface 62 is freefrom light diffusing agent particles. The surface 58 having prismstructures with projections are integrally formed with thelight-diffusing surface 62 at the back surface of the substrate material66.

U.S. Pat. No. 5,598,280 also discloses an alternate embodiment, a Type-Dmultifunctional film 70, in which surface micro-prism projections 78 areformed on the top surface of the substrate 76, integrally with formingthe light-diffusing surface of a separate coating layer 72 after it hasbeen applied to the back surface of substrate 76.

The multifunctional sheets mentioned above all have their shortcomings.In particular, optical coupling effect (e.g., the presence of Newtonianrings) is the primary problem with the type-A sheets due to their flat,non-structured bottom surface. The type-B and type-D sheets all have tobe made with a multiple-pass process, which makes them more susceptibleto defect formation, not to mention increasing production costs. Formanufacturing type-C sheets, due to the nature of extrusion processesand the single sheet of material configuration, it is more difficult tomake different structures on both side of the sheet simultaneous, andthe light enhancing and diffusing capabilities at the respective sidesof the single layer configuration is generally less than that ofmulti-layer configuration.

What is needed is optical structure that both enhances brightness andprovides effective diffusion, and overcoming the shortcomings of theprior art multifunctional optical sheet.

SUMMARY OF THE INVENTION

The present invention is directed to a luminance enhancement film havinga built-in light diffusing structure. The inventive luminanceenhancement film comprises an optical substrate that possesses astructured surface that enhances luminance or brightness, and a supportsubstrate that incorporates a dispersion of particles for lightdiffusion. In accordance with the present invention, a separate particlelayer is not required in addition to the support substrate layer. Theparticles are integrated in the unitary body of the support substratelayer.

In one aspect of the present invention, the particles are dispersed nearat least one of the planar surfaces of the support substrate (i.e., thelight input surface light output surface or both of the supportsubstrate. The extent of particles dispersion into the surface of thesupport substrate is significantly less than the thickness of thesupport substrate. The region of particles at the surface of the supportsubstrate is of a thickness on the order of the particle size. In oneembodiment, the thickness of the particle region is less than theaverage size of the particles (i.e., the particles protrude the surfaceof the support substrate).

All of the particles may be embedded below the surface of the supportsubstrate (i.e. all of the particles are disposed in a region below thesurface of the support substrate, wherein the thickness of the region issmaller than the thickness of the support substrate), or some of theparticles may protrude above the surface of the support substrate. Inone embodiment of the present invention, the support substrate containsparticles or beads that are dispersed only close to its surface and formprotrusions at the surface (i.e., the particle dispersed surface is notsmooth). The particles may be dispersed on one side or both planar sidesof the support substrate.

The particles and beads in the support substrate can be inorganic ororganic material, or a combination mixture of both. The shape of theparticles may be regular, irregular, symmetrical or non-symmetrical,having random or specific geometrical shapes (e.g., spherical,ellipsoidal, rhomboidal, disc, hollow or exotic shapes). The surface ofthe particles may be finished, e.g., polished, matte, painted, orcoated.

The characteristic size of particles and beads does not have to beuniform. All particles may be generally or substantially the same size,or have random sizes, or with a particular size distribution profileacross the substrate and/or in depth in reference to the supportsubstrate surface. In addition to particle size distribution, thedensity of particles can be evenly distributed across the surface of thesupport substrate or be distributed randomly across the surface of thesupport substrate, or distributed with varying particle density profilesacross the surface of the support substrate. In the alternate or inaddition, the particles can be evenly distributed in depth near thesurface of the support substrate or be distributed randomly in depthnear the surface of the substrate, or distributed with varying particledensity profiles in depth near the surface of the support substrate.Further, vary density profiles may include particle density being highercloser to the surface than the interior of the substrate, or vice versa.

The multifunctional luminance enhancement sheet made with a built-inlight diffusing surface in the support substrate can reduce the effectof the Newtonian rings. This is an advantage over the prior art Type-Aprism multifunctional luminance enhancement sheet. One advantage of thisinvention over the Type-B and Type-D sheets is that it eliminates theneed of an extra coating layer. The present invention avoids extrusionprocess and a single material configuration, an advantage of presentinvention over Type-C sheet. Using particles dispersed in the supportsubstrate instead of forming light-diffusing surface on a separate baselayer attached to the support substrate, the chance for light to bumpinto particles and being refracted is reduced, thereby improves overType-D sheets.

Another advantage of the present invention is that it reduces thethickness of multifunction sheet and eventually the thickness of thebacklight structures, which is becoming increasingly important in thedesign of display devices.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and advantages of theinvention, as well as the preferred mode of use, reference should bemade to the following detailed description read in conjunction with theaccompanying drawings. In the following drawings, like referencenumerals designate like or similar parts throughout the drawings.

FIG. 1 schematically illustrates a sectional view of a prior artbacklight module for LCD.

FIGS. 2 to 7 schematically illustrate the structures of various priorart multifunctional films.

FIG. 8 schematically illustrates the structure of an LCD having aluminance enhancement film in accordance with one embodiment of thepresent invention.

FIG. 9A is a schematic sectional view of a support substrateincorporating a dispersion of particles, in accordance with oneembodiment of the present invention;

FIG. 9B is a schematic sectional view of a luminance enhancement filmincorporating the support substrate of FIG. 9A, in accordance with oneembodiment of the present invention.

FIG. 10A is a SEM photograph of top view of a substrate incorporating adispersion of particles in accordance with one embodiment of the presentinvention; FIG. 10B is a SEM photograph of sectional view of thesubstrate in FIG. 10A.

FIG. 11 is a schematic view of an electronic device comprising an LCDpanel that incorporates the inventive luminance enhancement film of thepresent invention, in accordance with one embodiment of the presentinvention.

FIG. 12 is a schematic diagram explaining the components of total lighttransmittance through a film (e.g., support substrate, luminanceenhancement film, etc.).

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The present description is of the best presently contemplated mode ofcarrying out the invention. This invention has been described herein inreference to various embodiments and drawings. This description is madefor the purpose of illustrating the general principles of the inventionand should not be taken in a limiting sense. It will be appreciated bythose skilled in the art that variations and improvements may beaccomplished in view of these teachings without deviating from the scopeand spirit of the invention. The scope of the invention is bestdetermined by reference to the appended claims.

The present invention is directed to a luminance enhancement film (i.e.light redirecting film) comprising an optical substrate that possesses astructured surface that enhances luminance or brightness, and a supportsubstrate that incorporates a dispersion of particles for lightdiffusion (or scattering). In accordance with the present invention, aseparate particle layer is not required in addition to the supportsubstrate layer. The particles are integrated in the support substratelayer. The light redirected by the support substrate with the particleshas a less directionality than the light redirected by the supportsubstrate without the particles.

In one aspect of the present invention, the particles are dispersed nearat least one of the planar surfaces of the support substrate (i.e., thelight input surface light output surface or both of the supportsubstrate to provide optical diffusion. The optical diffusion aspect ofthe support substrate of the present invention is applicable toluminance enhancement films having optical substrates with various typesof structured light output surfaces designed for luminance enhancements.

FIG. 8 illustrates an example of a flat panel display. A backlight LCD110, in accordance with one embodiment of the present invention,comprises a liquid crystal (LC) display module 112, a planar lightsource in the form of a backlight module 114, and one or more luminanceenhancement films 126 and 128 of the present invention interposedbetween the LC module 112 and the backlight module 114. The luminanceenhancement films 126 and 128 may be similar. The LC module 112comprises liquid crystals sandwiched between two transparent substrates,and control circuitry defining a two-dimensional array of pixels. Thebacklight module 114 provides planar light distribution, either of thebacklit type in which the light source extends over a plane, or of theedge-lit type as shown in FIG. 8, in which a linear light source 116 isprovided at an edge of a light guide 118. A reflector 120 is provided torecycle light from the light guide 118 back into the light guide 118.The light guide 118 is structured (e.g., with a tapered plate and lightreflective and/or scattering surfaces defined on the bottom surfacefacing away from the LC module 112) to distribute and direct lightthrough the top planar surface facing towards LC module 112.

In the illustrated embodiment, there are two luminance enhancement films126 and 128, which are identical, in accordance with the presentinvention, which are arranged with the similar films offset by 90degrees about an axis perpendicular to the plane of the films (e.g., forfilms having longitudinal prism structures, the films are arranged withthe longitudinal prism structures generally orthogonal between the twofilms). The light entering the LC module 112 through the luminanceenhancement films is diffused and directed uniformly spatially over theplanar area of the LC module 112 and has relatively strong normal lightintensity. The luminance enhancement films in accordance with thepresent invention may be used with LCDs to be deployed for displays, forexample, for televisions, notebook computers, monitors, portable devicessuch as cell phones, PDAs and the like, to make the displays brighter.

FIG. 9A shows cross-section view of a support substrate 132 withparticles 140 dispersed at its surfaces. While FIG. 9A shows theembodiment with particles at both opposing surfaces of the supportsubstrate 132, it is understood that the particles 140 may be dispersedat only one of the surface of the support substrate 132 (e.g., withoutparticles at the bottom surface, or the light input surface 146). Theparticles are dispersed into the one or both surfaces while thesubstrate 132 is being formed. The optical substrate 130 material isthen adhered to the support substrate 132 and is embossed and cured toform the prism structures 135 and the two-layer multifunction film 126shown in FIG. 9B. While FIG. 9B shows the base substrate 142 to be ofuniform thickness, it may be of non-uniform thickness.

For ease of reference, the following orthogonal x, y, z coordinatesystem would be adopted for the various directions. As shown in FIG. 9B,the x-axis is in the direction across the peaks and valleys of thestructured surface, also referred to as the lateral direction. Thez-axis is perpendicular to the plane of the optical substrate 130. Lightfrom the external light guide 118 is directed in the positivez-direction in the illustrated embodiment. The y-axis is orthogonal tothe x-axis and z-axis, in the plane of the optical substrate 130. (For arectangular piece of the optical substrate, the x and y-axes would bealong the orthogonal edges of the substrate 130. The z-axis isorthogonal to the x and y-axes.)

The optical substrate 130 has a light input surface 142 that is planarand smooth, and a light output surface 144 that is structured (e.g.,prismatic structures comprising longitudinal regular prism blocks 135 inthe y-direction, and arranged in lateral rows (i.e., side-by-side in thex-direction) as shown in FIG. 9B). The prism blocks 135 are connected toadjoining prism blocks 135 in longitudinal and/or lateral directions.Because the prism blocks 135 are not in fact individual discrete blocksassembled together, the material of the prism blocks 135 are in acontinuum or continuous monolithic structure, with no physical contactsurfaces or joining surfaces per se.

In one embodiment of the present invention, the light output surface 144and the light input surface 142 are generally parallel to each other inthe overall optical substrate structure (i.e., do not form an overallsubstrate structure that is generally tapered like a light guide platein a backlight module, or that is concave or convex).

The prism blocks 135 may be regular or irregular (as disclosed inco-pending U.S. patent application Ser. No. 11/450,145, commonlyassigned to the assignee of the present invention, and is fullyincorporated by reference herein). References to cross sections of aprism block 135 would be sections taken in x-z planes, at variouslocations along the y axis. Further, references to a horizontaldirection would be in an x-y plane, and references to a verticaldirection would be in the z-direction. In the illustrated embodiment,the prism blocks 135 are regular in geometry. The light input surface142 lies in an x-y plane. The edge showing the ends of the lateral rowsof the prism blocks 135 lies in the x-z plane, such as shown in FIG. 9B.The prism blocks 135 may possess a structure having structure, geometryand features that are disclosed in earlier filed co-pending U.S. patentapplication Ser. Nos. 11/450,145 and 11/635,802, which have beencommonly assigned to the assignee of the present invention, and whichhad been incorporated by reference herein.

All the particles 140 may be embedded below the surface of the substrate132, or some of the particles 140 may protrude above the surface of thesubstrate 132. In one embodiment of the present invention, the supportsubstrate 132 may be a PET (polyethylene terephthalate) material. ThePET substrate 132 used in the present invention is made using regularmelt casting/stretching process. The PET substrate 132 is flexible andcontains particles or beads 140 that are dispersed only close to itssurface and form protrusions at the surface (i.e., the particledispersed surface is not smooth). The particles 140 may be dispersed onone side (e.g., the light output side 148 of the support substrate 132)or both planar sides (i.e., the light input side 146 and the lightoutput side 148) of the support substrate 132. The particles may cover adepth (i.e., the “a-region” thickness described later below) of 1-10%,preferably 1-5% of total substrate thickness at each of the planarsurfaces of the substrate 132 where particles are present. Givenparticle sizes on the order of less than 1-30 μm, and a-region thicknessof 1-5% of the support substrate thickness is on the order of less than1-20 μm (i.e., the particle size is on the order of the a-regionthickness, the particles are generally expected to protrude above theflat surface of the support substrate 132, unless for the smallerparticles in relation to larger depth of the particle region at thesurface. The protruded particles cause roughness at the light outputsurface 148 and light input surface 146 of the support substrate.

The particles 140 dispersed on the two sides of the support substrate132 can be made same or different in terms of any or all of material,chemical and/or physical composition, average size, weight loadinglevel, shape, surface properties, etc., and the a-region thicknessand/or particle distribution density may be different on the two sides.

The particles and beads in the PET substrate 132 can be inorganic ororganic in nature, i.e. Tio2, BaSO4, Silicone, SiO2, PS (polystyrene) orPMMA (polymethylmethacrylate). The characteristic, averaged size ofparticles and beads, as measured by known laser scattering method, canrange from 1 to 30 μm. Unless otherwise specifically noted or is clearfrom the context of the disclosure hereinbelow, all references toparticle or bead size refer to averaged size. The averaged size ofparticles and beads does not have to be uniform. All particles may begenerally or substantially the same size, or have random sizes, or witha particular size distribution profile across the substrate and/or indepth in reference to the support substrate surface. For example, forcross-linked PMMA, cross-linked PS and silicone beads, the particle sizecan range from 1 to 30 μm within a support substrate, with a preferredrange of 2 to 20 μm. For SiO2, TiO2 and BaSO4 particles, the particlesizes could vary from 0.3 to 5 μm, with preferred range of 1 to 3 μm.The afore-mentioned ranges are especially applicable to supportsubstrates 132 having thickness ranging from about 25 μm to 350 μm.Accordingly, the particle size, and the thickness of the particle region(the “a-region” described below), are significantly smaller than thethickness of the support substrate 132.

Generally, more uniform particle size distribution would provide a moreuniform light diffusion effect and higher light transmittance, but anon-uniform light diffusion effect may be intentionally achieved byselecting a desired size distribution (e.g., to complement a non-uniformlight source, or to intentionally provide a desired non-uniform lightintensity viewing appearance to a user.) As will be referenced below,“mono-dispersed” particles refer to particles having uniform bead sizein the support substrate, and poly-dispersed” particles refer toparticles having bead sizes within a certain size distribution in thesupport substrate. As the terms are applied herein, “mono-dispersed”particles are deemed to be particles having actual sizes ranging withina co-efficient of variation (CV) that is 15% of less.

In addition to particle size distribution, the particles 140 can beevenly distributed across the surface of the support substrate 132 or bedistributed randomly across the surface of the substrate 132, ordistributed with varying particle density profiles across the surface ofthe substrate 132. In the alternate or in addition, the particles 140can be evenly distributed in depth near the surface of the substrate 132or be distributed randomly in depth near the surface of the substrate132, or distributed with varying particle density profiles in depth nearthe surface of the substrate 132. Further, vary density profiles mayinclude particle density being higher closer to the surface than theinterior of the substrate, or vice versa.

The shape of the particles 140 may be regular, irregular, symmetrical,or non-symmetrical, having random or specific geometrical shapes (e.g.,spherical, ellipsoidal, rhomboid, disc, etc.). For example, inorganicbeads, e.g., SiO2, BaSO4 and TiO2, may be randomly shaped. The organicbeads, e.g., cross-linked PMMA and cross-linked PS or silicone, may bespherical, hollow or exotic shape (e.g., biconvex lens shape).

FIGS. 10A and 10B show SEM photos of top view and cross-section view ofa support substrate including a dispersion of particles at its surface.The tested material of the support substrate is PET and the particlesused are SiO2. All the particles are spotted on the proximity of outersurface. The total particles used on each surface are 0.009% to 0.2% oftotal substrate weight. Alternatively, the amount of particles used iscontrolled by reference to volume of the particles.

The particles 140 have a white appearance under light. The surface ofthe particles 140 may be finished, e.g., polished, matte, painted, orcoated.

The refractive index of exemplar materials for the substrate 132 andparticle 140 include:

-   PET substrate ^(˜)1.50    Particles:-   SiO2 ^(˜)1.46-   BaSO4 ^(˜)1.65-   TiO2 ^(˜)2.49-   Cross-linked PMMA ^(˜)1.49-   Cross-linked PS ^(˜)1.59-   Silicone ^(˜)1.43

Several design criteria are being considered for the support substrate132 and the resultant luminance enhancement film 126, includingcharacteristics of the support substrate such as transmittance,diffusion, and haze, and optical gain (i.e., the light collectioncapability) of the resultant luminance enhancement film. Further, it isdesired to eliminate Newton-ring effect and reduce rainbow effect in thesupport substrate.

Referring to FIG. 12, the total light transmittance through a film(e.g., support substrate, luminance enhancement film, etc.) includesseveral components. As applied to the support substrate film, the totallight transmittance includes a component of parallel transmitted lightand a diffused transmitted light. In particular, total lighttransmittance (% Tt)=(Total light transmitted/incidentlight)×100=Parallel light transmittance (% Pt)+Diffuse lighttransmittance (% Df). In addition, Haze (Hz) is defined to be (% Df/%Tt)×100. Generally, for the support substrate 132 to provide effectivediffusion effect, it is desirable to have as high a % Tt as possible,and with as high a % Df component as possible, or to have Hz to be ashigh as possible, but not to high as to significantly compromise Tt.

Several factors or parameters affect the transmittance and diffusion ofthe luminance enhancement film 126 of the present invention. Some of theparameters may include:

a. Ra of the surface of the support substrate 132 (Ra is defined, e.g.,by Handbook of Surface Metrology, David J. Whitehouse, CRC Press(1994)). (Ra generally increases with increase in bead size, beadloading, and thickness of “a-region” (see below));

b. average size of the particles;

c. size variation and distribution of the particles (e.g., mono v.poly-dispersed);

d. density distribution of the particles;

e. loading (e.g., wt %) of particles in the support substrate (e.g.,1-10%);

f. properties of layers of the support substrate (e.g., particles atonly one planar side of the support substrate (i.e., abb-typesubstrate), or particles at both sides of the support substrate (i.e.,aba-type substrate). The designation of “a” refers to a surface regionwithin the support substrate with particles, “b” refers to the coreregion and/or surface region within the support substrate withoutparticles. There is however no boundary, physical or chemical, betweenthe “a” and “b” regions. The “a” and “b” regions are in a continuum orcontinuous, unitary or monolithic structure, with no physical contactsurfaces or joining surfaces per se between the region. Accordingly,abb-type substrate refers to a support substrate having a surface regionhaving particles, a core region of no particle, and another surfaceregion of no particle; aba-type substrate refers to a support substratehaving a core region of no particle sandwiched by two surface regionshaving particles.);

g surface properties of particles (e.g., reflective and refractiveproperties),

h. average thickness or depth of particle region near surface (i.e.,thickness of the a-region or a-“layer”),

i. shape of particles.

Generally, in order to improve the light transmittance through thesubstrate 140, the surface of beads/particles 140 can be chemicallymodified to make its surface refractive index closer to that of thematerial of the substrate 140. The surface of the particles 140 may alsobe reflective (e.g., with a polished or coated surface, or madereflective based on difference in refractive indices of the particlesand substrate.) Both differences in refractive indices and size andshape of particle/bead 140 affect the diffusion effect of the particles140 at the surface of the support substrate 132. The difference inrefractive indices and size and shape of particle/bead 140 will be themain factors on determining the effectiveness of diffusion. The locationof particle/bead 140 is a lesser factor.

In the illustrated embodiment, the average surface roughness (Ra) of theparticle dispersed PET substrate 132 is between 0.1 and 1 μm (e.g. basedon ISO4287). The transparent material may be flexible and of materialsincluding but not limited to PET and polycarbonate. The material may beclearly transparent or may have a color to it. The transparent materialmay also be rigid and of materials including but not limited to PET,acrylic and polycarbonate and its co-polymers.

Based on experiments conducted comparing support substrates (of PETmaterial) by varying various structural parameters, and furthercomparing the resultant luminance enhancement films incorporating therespective support substrates, the following relative effects wereobserved:

a. Effects of aba-type vs. abb-type support substrates: Comparing two 50μm thick support substrates, having 3 μm poly-dispersed PMMA beads, withcomparable particle a-region thickness (e.g., about 1.5 μm) and Ra ofthe support substrate surface, and other comparable parameters, similar% Df and haze can be achieved with less total bead loading for theabb-type support substrate (e.g., 5% bead loading for the abb-type and4% bead loading for each planar side of the aba-type (total 8%)), andwith more effective Newton-ring elimination. In other words, forabb-type, Newton-ring can be eliminated by using less beads.

b. Effects of a-region thickness: Comparing two 50 μm thick abb-typesupport substrates, both having 3 μm poly-dispersed PMMA beads, and 5 wt% loading of particles with comparable Ra of the support substratesurface, and other comparable parameters, increasing the thickness ofthe particle region (i.e., the a-region or a-layer) near the surface ofthe support substrates (e.g., from 1.56 to 2.20 μm) would only slightlyincreases % Df. However, it has been found that in the resultantluminance enhancement films, the one with the support substrate havingthe thicker a-region has a lower optical gain.

c. Effects of bead type: Comparing three 50 μm thick, abb-type supportsubstrates respectively having poly-dispersed PMMA, mono-dispersed PMMA,and mono-dispersed PS particles, with about 5 wt % loading of particles,and about similar 1.5 μm a-region thickness, about similar 3 μm averagesize beads, with comparable Ra of the support substrate surface, andother comparable parameters, the results show (i) the mono-dispersedparticles show better diffusion effect, and (ii) the mono-dispersed PSparticles provide slightly higher haze and % Df then mono-dispersedPMMA, but provides higher optical gain in the resultant luminanceenhancement films. It also appears that there is no correlation between% Df of the support substrate and optical gain of the resultantluminance enhancement film.

d. Effects of bead size and a-region thickness: Comparing three 125 μmthick aba-type support substrates, all with about 3 wt % loading ofpoly-dispersed PMMA beads, having 3 μm, 6 μm and 6 μm bead sizes,respectively, at each of both planar sides of the respective supportsubstrates, and other comparable parameters, the results show (i) theeffect of diffusion decreases when the average bead size increase, (ii)with same type of beads, % Df can be increased by increasing thea-region thickness (e.g. from 2.7 to 5.5 μm); (iii) the bead size showlittle effect on rainbow effect, and (iv) the rainbow effect can besuppressed by increasing the a-region thickness, but that would reducethe optical gain in the resultant luminance enhancement film.

e. Effects of aba-type vs. abb-type for 125 μm substrates: Comparingthree 125 μm thick support substrates, having 3 μm poly-dispersed PMMAbeads, with 3% bead loading of 2.72 μm a-region thickness at each of thetwo planar surfaces of the aba-type, 6% bead loading at 3.9 μm a-regionthickness at one surface of a first abb-type and 10% at 3.9 μm a-regionthickness at one surface of a second abb-type, the results show (i) withthe same % bead loading, abb-type has lower % Df and haze, but resultantluminance enhancement film with the abb-type film has similar % Df andshows better reduction of rainbow effect, (ii) increase in loading ofbeads can eliminate rainbow effect completely, but the optical gain ofresultant luminance enhancement films will be reduced.

f. Effects of aba-type vs. abb-type for 125 μm substrates: Comparing two125 μm thick support substrates, having 6 μm poly-dispersed PMMA beads,with 3% bead loading of 2.72 μm a-region thickness at each of the twoplanar surfaces of the aba-type, 3% bead loading at 3.9 μm a-regionthickness at one surface of the abb-type, the results show (i) with onlyone a-region in the abb-type (i.e., less total bead loading), the % Dfis reduced without affecting % Tt, and (ii) the Newton-ring is notpresent even with half the total bead loading for the abb-type. Further,the optical gain of the resultant luminance enhancement films isimproved for the abb-type. g. Effects of bead type for 125 μmsubstrates: Comparing two 125 μm thick support substrates havingpoly-dispersed PMMA particles at 3.9 μm a-region thickness, with 3%loading of poly-dispersed PMMA of 6 μm bead size and 4.5% loading ofmono-dispersed PMMA of 5 μm bead size, the results show comparable % Ttfor both substrates, but slightly lower % Df for the larger bead size.However, for the resultant luminance enhancement films, the overalloptical gains are comparable between the two.

h. Effects of particle loading: Comparing two 100 μm thick abb-typesupport substrates having mono-dispersed PS particles of 5 μm bead sizeat 3.1 μm a-region thickness, between 3.5% loading and 5.5% loading, theresults show the increase of bead loading increases % Df and haze asexpected.

i. Effects of bead loading on rainbow elimination: It has been foundthat the bead loading needs to reach certain threshold level (e.g.,between 3.5 to 5.5%) in order to suppress the rainbow effect.

j. Effects of particle size for 188 μm substrate: Comparing two 188 μmthick abb-type support substrates, both with 3 wt. % loading ofpoly-dispersed PS beads, having 6 μm and 8 μm bead sizes, respectively,at one planar side of the respective support substrates, the resultsshow for the same bead loading and a-region thickness, Ra increases withlarger particle size.

In addition to the above experiments, it is expected that the prismstructure selected in the optical substrate of the luminance enhancementfilm could affect various optical effects, including rainbow effect.However, the overall optical gain could be affected as a result.However, it is expected that rainbow can be eliminated with PET filmdesign regardless of prism type.

The prism structures at the structured optical substrate 130 may beimperfect, meaning that the peaks of the prisms may be at a decreasingangle, may be rounded, or may be smoothed by a variable radius curve inproximity of the peak. This may be an advantage for decreasing thedamage to the patterned materials in handling. It may also be anadvantage for softening the drop-off in brightness from the relativelysharp cut-off that can be theoretically achieved by use of perfect prismstructures.

In one embodiment, the particles/beads 140 can be metered into thesupport substrate 132 by pre-mixing with melted PET resin through aseparate PET resin supply channel of the substrate forming equipment,and forming on the surface when the pre-substrate is being bi-axiallystretched. Other than the application of particles into the mix, thisprocess is known to those skilled in the art.

The multifunctional luminance prism sheet is preferably produced in a UVCast-Cure process that is well known to those skilled in the art. Theprism pattern is placed on the support substrate 132 by use of a rollthat has been machined with the negative shape of the pattern. Thispattern on the roll is created by diamond turning the pattern on theroll using techniques that are well known to those skilled in the art.

Alternative production techniques include extrusion, UV-cast-curecoating, calendaring, embossing, injection molding andcompression-injection molding. Tools may be in the form of rolls, beltsor mold plates or mold inserts. Techniques for forming the pattern onthe tools include but are not limited to use of diamond tipped tools asin diamond turning, lithography, laser ablation, extrusion or lasercutting.

As an example to illustrate the relative dimensions of an opticalsubstrate in accordance with the present invention, the peak heights areon the order of 10 to 200 micrometers, the valley heights (bottomthickness) are on the order of 0.3 to 10 micrometers. The foregoingdimensions are intended to illustrate the fact that the structuredsurface features are microstructures, in the micrometers range. By wayof example, the overall size of the area of the luminance enhancementfilm may vary on the order of 2 mm to 10 m in both width and length (andeven larger dimensions possible), depending on the particularapplication (e.g., in a flat panel display of a cellular phone, or in asignificantly larger flat panel display of a TV monitor). Thecharacteristic size of the prism blocks on the structured surface of theoptical substrate need not change appreciably with different overalloptical substrate size.

The structured surface 144 of optical substrate 130 may be generated inaccordance with a number of process techniques, including micromachiningusing hard tools to form molds or the like for the prismatic profilehaving the predefined structural irregularities described above. Thehard tools may be very small diamond tools mounted on CNC (ComputerNumeric Control) machines (e.g. turning, milling and ruling/shapingmachines). Furthermore, known STS (Slow Tool Servo) and FTS (Fast ToolServo) are examples of the devices. U.S. Pat. No. 6,581,286, forinstance, discloses one of the applications of the FTS for makinggrooves on an optical film by using thread cutting method. To providepredefined structural irregularities, these machines may include certainperturbation means to assist the tools moving with small shifts andmaking prisms, and hence non-facet flat irregularities having differentlevels of irregularities. Known STS, FTS may include ultrasonicvibration apparatus to provide perturbation or vibration to accomplishstructural irregularities predefined in the mold. By using the devicesto form surfaces in the mold in relation to increasing degrees offreedom, three-dimensionally varying regular and/or irregular prisms andflats of the structured surfaces of the optical substrates disclosedabove can be obtained.

The master may be used to mold the optical substrate 130 directly orused in electroforming a duplicate of the master, which duplicate isused to mold the optical substrate. The mold may be in the form of abelt, a drum, a plate, or a cavity. The mold may be used to form theprismatic structure on a substrate through hot embossing of thesubstrate, and/or through the addition of an ultraviolet curing orthermal setting materials in which the structures are formed. The moldmay also be used to form the optical substrate through injectionmolding. The substrate or coating material may be any organic, inorganicor hybrid optically transparent material and may include suspendeddiffusion, birefringence or index of refraction modifying particles.

In accordance with one embodiment of the present invention, the LCD 110in FIG. 8 incorporating the inventive luminance enhancement film inaccordance with the present invention may be deployed in an electronicdevice. As shown in FIG. 11, an electronic 1110 (which may be one of aPDA, mobile phone, television, display monitor, portable computer,refrigerator, etc.) comprises the inventive LCD 110 (FIG. 8) inaccordance with one embodiment of the present invention. The LCD 110comprises the inventive optical substrate described above. Theelectronic device 1110 may further include within a suitable housing, auser input interface such as keys and buttons (schematically representedby the block 1116), image data control electronics, such as a controller(schematically represented by block 1112) for managing image data flowto the LCD panel 110, electronics specific to the electronic device1110, which may include a processor, A/D converters, memory devices,data storage devices, etc. (schematically collectively represented byblock 1118), and a power source such as a power supply, battery or jackfor external power source (schematically represented by block 1114),which components are well known in the art.

While particular embodiments of the invention have been described hereinfor the purpose of illustrating the invention and not for the purpose oflimiting the same, it will be appreciated by those of ordinary skill inthe art that numerous variations of the details, materials, andarrangements of parts may be made without departing from the scope ofthe invention as defined in the appended claims.

What is claimed is:
 1. A method of forming a light enhancement film,wherein the light enhancement film has a light input surface and a lightoutput surface opposite to the light input surface, wherein the methodcomprises: providing a support substrate comprising a unitary body madeof an organic material, wherein the unitary body has a first surface anda second surface opposite to the first surface, wherein the firstsurface defines the light input surface of the light enhancement film;mixing a plurality of organic particles and a plurality of inorganicparticles to form mixed particles, wherein the plurality of organicparticles and the plurality of inorganic particles are used forlight-diffusing; adding the mixed particles into the unitary body,wherein the plurality of inorganic particles are mixed with theplurality of organic particles to increase degree of uniformity of theplurality of inorganic particles in the unitary body made of the organicmaterial; and forming a structured layer on the unitary body, whereinthe structured layer has a third surface and a fourth surface oppositeto the third surface, wherein the third surface of the structured layeris disposed on the second surface of the unitary body and the fourthsurface defines the light output surface of the light enhancement film.2. The method according to the claim 1, wherein the material of theunitary body is different from the material of the structured layer. 3.The method according to the claim 1, wherein the organic material isPET.
 4. The method according to the claim 1, wherein the mixed particlesare disposed in a surface region of the first surface of the unitarybody, wherein the thickness of the surface region is smaller than thethickness of the unitary body.
 5. The method according to the claim 1,wherein the mixed particles are disposed in a region of the unitary bodybelow the first surface of the unitary body, wherein the thickness ofthe region is smaller than the thickness of the unitary body.
 6. Themethod according to the claim 1, wherein the mixed particles aredisposed in a surface region of the second surface of the unitary body,wherein the thickness of the surface region is smaller than thethickness of the unitary body.
 7. The method according to the claim 1,wherein at least one portion of the mixed particles protrude from thefirst surface of the unitary body so as to cause roughness in the firstsurface of the unitary body.
 8. The method according to the claim 1,wherein the particle density of the mixed particles varies in athickness direction of the unitary body.
 9. The method according to theclaim 8, wherein the unitary body comprises a first point and a secondpoint closer to the first surface of the unitary body than the firstpoint, wherein the particle density at the first point is larger thanthe particle density at the second point.
 10. The method according tothe claim 8, wherein the unitary body comprises a first point and asecond point closer to the first surface of the unitary body than thefirst point, wherein the particle density at the first point is smallerthan the particle density at the second point.
 11. A light enhancementfilm having a light input surface and a light output surface opposite tothe light input surface, comprising: a support substrate comprising aunitary body having a first surface and a second surface opposite to thefirst surface, wherein the first surface defines the light input surfaceof the light enhancement film; and a structured layer having a thirdsurface and a fourth surface opposite to the third surface, wherein thethird surface of the structured layer is disposed on the second surfaceof the unitary body and the fourth surface defines the light outputsurface of the light enhancement film; wherein the unitary body is madeof an organic material and comprises mixed particles composed of aplurality of organic particles and a plurality of inorganic particles,wherein the plurality of organic particles and the plurality ofinorgoanic particles are used for light-diffusing, wherein the pluralityof inorganic particles are mixed with the plurality of organic particlesto increase degree of uniformity of the plurality of inorganic particlesin the unitary body made of the organic material.
 12. The lightenhancement film according to the claim 11, wherein the material of theunitary body is different from the material of the structured layer. 13.The light enhancement film according to the claim 11, wherein theorganic material is PET.
 14. The light enhancement film according to theclaim 11, wherein the mixed particles are disposed in a surface regionof the first surface of the unitary body, wherein the thickness of thesurface region is smaller than the thickness of the unitary body. 15.The light enhancement film according to the claim 11, wherein the mixedparticles are disposed in a region of the unitary body below the firstsurface of the unitary body, wherein the thickness of the region issmaller than the thickness of the unitary body.
 16. The lightenhancement film according to the claim 11, wherein at least one portionof the mixed particles protrude from the first surface of the unitarybody so as to cause roughness in the first surface of the unitary body.17. The light enhancement film according to the claim 11, wherein theparticle density of the mixed particles varies in a thickness directionof the unitary body.
 18. The light enhancement film according to theclaim 17, wherein the unitary body comprises a first point and a secondpoint closer to the first surface of the unitary body than the firstpoint, wherein the particle density at the first point is larger thanthe particle density at the second point.
 19. The light enhancement filmaccording to the claim 17, wherein the unitary body comprises a firstpoint and a second point closer to the first surface of the unitary bodythan the first point, wherein the particle density at the first point issmaller than the particle density at the second point.
 20. An opticalfilm, comprising: a support substrate comprising a unitary body having afirst surface and a second surface opposite to the first surface; and astructured layer having a third surface and a fourth surface opposite tothe third surface, wherein the third surface of the structured layer isdisposed on the second surface of the unitary body; wherein the unitarybody is made of an organic material and comprises mixed particlescomposed of a plurality of organic particles and a plurality ofinorganic particles, wherein the plurality of organic particles and theplurality of inorganic particles are used for light-diffusing, whereinthe plurality of inorganic particles are mixed with the plurality oforganic particles to increase degree of uniformity of the plurality ofinorganic particles in the unitary body made of the organic material.